Smart Manufacturing &
Industrial IoT
Drive Industry 4.0 transformation with smart manufacturing solutions. From IoT integration to predictive maintenance, we build systems that optimize production and reduce downtime.
Industry Challenges We Solve
Common pain points in manufacturing & industrial iot solutions
Legacy Equipment Integration
Connecting modern IoT systems with decades-old manufacturing equipment.
Unplanned Downtime
Equipment failures causing costly production delays and maintenance.
Data Silos
Fragmented data across different systems preventing holistic insights.
Quality Consistency
Maintaining consistent product quality across shifts and production lines.
Our Solutions
Tailored solutions for manufacturing & industrial iot solutions
Industrial IoT & Sensor Integration
Connect machines, sensors, and equipment for real-time monitoring and data collection.
Predictive Maintenance Systems
ML-powered systems that predict equipment failures before they occur, reducing downtime.
Manufacturing Execution Systems (MES)
Track and document the transformation of raw materials to finished goods in real-time.
Digital Twin Development
Create virtual replicas of physical assets for simulation, optimization, and predictive analysis.
Our Process
How we deliver manufacturing & industrial iot solutions solutions
Manufacturing Assessment
Analyze production processes, equipment, data sources, and identify optimization opportunities.
IoT Architecture Design
Design sensor network, edge computing infrastructure, and data pipeline architecture.
System Development & Integration
Develop and integrate IoT sensors, predictive models, and manufacturing systems.
Deployment & Optimization
Phased rollout with training, monitoring, continuous improvement, and ROI tracking.
Why Choose Us for Manufacturing & Industrial IoT Solutions
Compliance & Certifications
Case Studies
Smart Factory Optimization Platform
A manufacturer struggled with low Overall Equipment Effectiveness (OEE) and frequent unplanned downtime.
Results
Predictive Maintenance System
Unexpected equipment failures were causing production losses and food safety risks.
Results
FAQs
How do you integrate with legacy manufacturing equipment?
We use industrial protocols (OPC UA, Modbus, Profinet), edge gateways, and retrofit sensors to connect legacy equipment. We can interface with PLCs, SCADA systems, and older machinery without disrupting production.
What is predictive maintenance and how accurate is it?
Predictive maintenance uses sensor data and machine learning to forecast equipment failures before they occur. Our systems typically achieve 90-95% accuracy, predicting failures 2-4 weeks in advance, allowing planned maintenance during scheduled downtime.
Can you integrate MES with our existing ERP system?
Yes, we have extensive experience integrating MES with major ERP systems (SAP, Oracle, Microsoft Dynamics) through APIs, middleware, and data synchronization. We ensure seamless data flow between shop floor and business systems for real-time visibility.
What ROI can we expect from smart manufacturing initiatives?
Typical ROI ranges from 200-400% within 18-24 months. Benefits include reduced downtime (20-40%), improved OEE (15-45%), lower maintenance costs (30-50%), energy savings (15-30%), and better quality control. We provide detailed ROI analysis during planning.
Ready to Transform Your Manufacturing?
Let's build a smart factory solution that optimizes production, reduces costs, and drives Industry 4.0 transformation.